Highly selective NOx sensor in the presence of NH3

ABSTRACT

An improved NO x  sensor with an NH 3  oxidation. A sensor module may include a support component, a NO x  sensing material positioned on the support component, and an NH 3  oxidation catalyst. The NH 3  oxidation catalyst may be layered on top of the NO x  sensing material or the NH 3  oxidation catalyst may be positioned upstream of the NO x  sensing material such that the NH 3  oxidation catalyst selectively converts NH 3  to N 2  while permitting NO x  through to the NO x  sensing material.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application a continuation of U.S. patent application Ser.No. 15/520,708, filed Apr. 20, 2017, which is a National PhaseApplication of PCT/US2014/062339, filed Oct. 27, 2014. The contents ofthese applications are hereby incorporated by reference in theirentireties.

TECHNICAL FIELD

The present application relates generally to the field of selectivecatalytic reduction (SCR) systems for an exhaust aftertreatment system.

BACKGROUND

For internal combustion engines, such as diesel engines, nitrogen oxide(NO_(x)) compounds may be emitted in the exhaust. To reduce NO_(x)emissions, a SCR process may be implemented to convert the NO_(x)compounds into more neutral compounds, such as diatomic nitrogen, water,or carbon dioxide, with the aid of a catalyst and a reductant. Thecatalyst may be included in a catalyst chamber of an exhaust system,such as that of a vehicle or power generation unit. A reductant, such asanhydrous ammonia, aqueous ammonia, or urea is typically introduced intothe exhaust gas flow prior to the catalyst chamber. To introduce thereductant into the exhaust gas flow for the SCR process, an SCR systemmay dose or otherwise introduce the reductant through a dosing modulethat vaporizes or sprays the reductant into an exhaust pipe of theexhaust system up-stream of the catalyst chamber. The SCR system mayinclude one or more sensors to monitor conditions within the exhaustsystem.

NO_(x) sensors may have some cross sensitivity to NH₃ compounds, andthis cross-sensitivity may cause errors in readings from the NO_(x)sensors and, consequently, decrease SCR performance efficiency.

SUMMARY

Various embodiments relate to a NO_(x) sensor that includes a supportcomponent, a NO_(x) sensing material positioned on the supportcomponent, and an NH₃ oxidation catalyst proximate to the NO_(x) sensingmaterial. In some implementations, the NH₃ oxidation catalyst may belayered upon the NO_(x) sensing material. The NH₃ oxidation catalyst maysubstantially cover the NO_(x) sensing material. The support componentmay include a sample chamber of a sensor barrel. In someimplementations, the NH₃ oxidation catalyst may coat a portion of aninterior of the sample chamber of the sensor barrel. In someimplementations, the NO_(x) sensing material may include a ceramic typemetal oxide. In particular embodiments, the NO_(x) sensing material mayinclude yttria-stabilized zirconia.

Other embodiments relate to a NO_(x) sensor that includes a supportcomponent, a NO_(x) sensing material positioned on the supportcomponent, and an NH₃ oxidation catalyst positioned upstream of theNO_(x) sensing material. In some implementations, the NH₃ oxidationcatalyst may be spaced apart from the NO_(x) sensing material. The NH₃oxidation catalyst may include an extruded catalyst. In otherimplementations, the NH₃ oxidation catalyst may include a coatedsubstrate. The support component may include a sample chamber of asensor barrel and the NH₃ oxidation catalyst may be affixed within thesample chamber of the sensor barrel and spaced apart from the NO_(x)sensing material. In some implementations, the NH₃ oxidation catalystmay coat a portion of an interior of the sample chamber of the sensorbarrel. The NO_(x) sensing material may include a ceramic type metaloxide. Thee NO_(x) sensing material may include yttria-stabilizedzircons. The NO_(x) sensor may further include a heating elementconfigured to heat the NH₃ oxidation catalyst.

Further embodiments relate to a method of manufacturing a NO_(x) sensorthat includes providing a support component, applying a NO_(x) sensingmaterial to the support component, and applying a NH₃ oxidation catalystto at least one of the support component or the NO_(x) sensing material.In some implementations the NH₃ oxidation catalyst may include a layerof NH₃ oxidation catalyst applied to the NO_(x) sensing material tosubstantially cover the NO_(x) sensing material. The layer of NH₃oxidation catalyst may be applied to a surface of the support component.The method of manufacturing the NO_(x) sensor may further includecoupling an electrode to the NO_(x) sensing material.

BRIEF DESCRIPTION

The details of one or more implementations are set forth in theaccompanying drawings and the description below. Other features,aspects, and advantages of the disclosure will become apparent from thedescription, the drawings, and the claims, in which:

FIG. 1 is a block schematic diagram of an example selective catalyticreduction system having an example reductant delivery system for anexhaust system;

FIG. 2 is a block diagram showing a NO_(x) sensing material and a NH₃catalyst material showing the oxidation of NH₃ to N₂ and O₂;

FIG. 3 is a block diagram of an example NO_(x) sensor having a NH₃catalyst positioned proximate a NO_(x) sensing material;

FIG. 4 is a block diagram of another example NO_(x) sensor having a NH₃catalyst positioned upstream of a NO_(x) sensing material;

FIG. 5 is a block diagram of another example NO_(x) sensor having a NH₃catalyst positioned upstream of a NO_(x) sensing material and havingindependent heating elements.

It will be recognized that some or all of the figures are schematicrepresentations for purposes of illustration. The figures are providedfor the purpose of illustrating one or more implementations with theexplicit understanding that they will not be used to limit the scope orthe meaning of the claims.

DETAILED DESCRIPTION

Following below are more detailed descriptions of various conceptsrelated to, and implementations of, methods, apparatuses, and systemsfor reducing or eliminating NH₃ from a sample of exhaust gas for aNO_(x) sensor. The various concepts introduced above and discussed ingreater detail below may be implemented in any of numerous ways, as thedescribed concepts are not limited to any particular manner ofimplementation. Examples of specific implementations and applicationsare provided primarily for illustrative purposes.

I. Overview

In some vehicles, NO_(x) may be produced with other compounds as aresult of combustion, such as for a diesel fuel vehicle, a diesel fuelpower generator, etc. In some exhaust systems, a sensor module may belocated upstream, downstream, or as part of an SCR catalyst to detectone or more emissions in the exhaust flow alter the SCR catalyst. Forexample, a NO_(x) sensor, a CO sensor, and/or a particulate mattersensor may be positioned downstream of the SCR catalyst to detectNO_(x), CO, and/or particulate matter within the exhaust gas exiting theexhaust of the vehicle. Such emission sensors may be useful to providefeedback to a controller to modify an operating parameter of theaftertreatment system of the vehicle. For example, a NO_(x) sensor maybe utilized to detect the amount of NO_(x) exiting the vehicle exhaustsystem and, if the NO_(x) detected is too high or too low, thecontroller may modify an amount of reductant delivered by a dosingmodule. A CO and/or a particulate matter sensor may also be utilized.

NH₃ compounds may be produced when urea or other NH₃ compounds are notreduced during the reduction of NO_(x) via the SCR catalyst. In suchinstances, a sample reading by a NO_(x) sensor may be offset based onthe amount of NH₃ present in the exhaust sample for some NO_(x) sensors.Various embodiments disclosed herein provide for a system to reduce oreliminate NH₃ compounds prior to a NO_(x) sensing portion of a NO_(x)sensor to reduce the error introduced by the NH₃ and/or to eliminate theneed to separately determine the amount of NH₃ in the exhaust sample tocorrectly determine the NO_(x) amount.

In some implementations, the NH₃ catalyst may be a separate componentfrom the NO_(x) sensor and positioned such that the NH₃ catalystoxidizes NH₃ compounds in the exhaust stream sample to be delivered tothe NO_(x) sensor (e.g., as an ammonia filter or substrate elementupstream of the NO_(x) sensor in the exhaust stream, in an exhaustsample tube, and/or combinations thereof). In other implementations, theNH₃ catalyst may be a part of the NO₃ sensor, but may be positionedseparate from the NO₃ sensing portion of the NO_(x) sensor (e.g., as anammonia filtering or substrate element within a sample chamber or tubeof the NO_(x) sensor, as a layer on a wall of a sample chamber or tubeof the NO_(x) sensor, and/or combinations thereof). In still furtherimplementations, the NH₃ oxidation catalyst may be a part of the NO_(x)sensor and may be positioned proximate to the NO_(x) sensing portion ofthe NO_(x) sensor (e.g., adjacent the NO₃ sensing portion, atop theNO_(x) sensing portion, below the NO_(x) sensing portion, and/orcombinations thereof). Any of the foregoing implementations may beutilized to reduce or eliminate NH₃ compounds prior to a NO_(x) sensingportion of a NO_(x) sensor such that the detection of NO_(x) within anexhaust sample may be improved. Such configurations may provide a moreaccurate NO_(x) measurement for different zones of an aftertreatment orexhaust system. In addition, such configurations may also improveammonia-to-NO_(x) (ANR) control and improve SCR efficacy.

II. Overview of Aftertreatment System

FIG. 1 depicts an aftertreatment system 100 having an example reductantdelivery system 110 for an exhaust system 190. The aftertreatment system100 includes a diesel particulate filter (DPF) 102, the reductantdelivery system 110, a decomposition chamber or reactor 104, a SCRcatalyst 106, and a sensor probe 150.

The DPF 102 is configured to remove particulate matter, such as soot,from exhaust gas flowing in the exhaust system 190. The DPF 102 includesan inlet, where the exhaust gas is received, and an outlet, where theexhaust gas exits after having particulate matter substantially filteredfrom the exhaust gas and/or converting the particulate matter intocarbon dioxide.

The decomposition chamber 104 is configured to convert a reductant, suchas urea, aqueous ammonia, or diesel exhaust fluid (DEF), into ammonia.The decomposition chamber 104 includes a reductant delivery system 110having a dosing module 112 configured to dose the reductant into thedecomposition chamber 104. In some implementations, the urea, aqueousammonia, DEF is injected upstream of the SCR catalyst 106. The reductantdroplets then undergo the processes of evaporation, thermolysis, andhydrolysis to form gaseous ammonia within the exhaust system 190. Thedecomposition chamber 104 includes an inlet in fluid communication withthe DPF 102 to receive the exhaust gas containing NO_(x) emissions andan outlet for the exhaust gas, NO_(x) emissions, ammonia, and/orremaining reductant to flow to the SCR catalyst 106.

The decomposition chamber 104 includes the dosing module 112 mounted tothe decomposition chamber 104 such that the dosing module 112 may dose areductant, such as urea, aqueous ammonia, or DEF, into the exhaust gasesflowing in the exhaust system 190. The dosing module 112 may include aninsulator 114 interposed between a portion of the dosing module 112 andthe portion of the decomposition chamber 104 to which the dosing module112 is mounted. The dosing module 112 is fluidly coupled to one or morereductant sources 116. In some implementations, a pump (not shown) maybe used to pressurize the reductant source 116 for delivery to thedosing module 112.

The dosing module 112 is also electrically or communicatively coupled toa controller 120. The controller 120 is configured to control the dosingmodule 112 to dose reductant into the decomposition chamber 104. Thecontroller 120 may include a microprocessor, an application-specificintegrated circuit (ASIC), a field-programmable gate array (FPGA), etc.,or combinations thereof. The controller 120 may include memory which mayinclude, but is not limited to, electronic, optical, magnetic, or anyother storage or transmission device capable of providing a processor,ASIC, FPGA, etc, with program instructions. The memory may include amemory chip, Electrically Erasable Programmable Read-Only Memory(EEPROM), erasable programmable read only memory (EPROM), flash memory,or any other suitable memory from which the controller 120 can readinstructions. The instructions may include code from any suitableprogramming language.

The SCR catalyst 106 is configured to assist in the reduction of NO_(x)emissions by accelerating a NO_(x) reduction process between the ammoniaand the NO_(x) of the exhaust gas into diatomic nitrogen, water, and/orcarbon dioxide. The SCR catalyst 106 includes inlet in fluidcommunication with the decomposition chamber 104 from which exhaust gasand reductant is received and an outlet in fluid communication with anend 192 of the exhaust system 190.

The exhaust system 190 may further include a diesel oxidation catalyst(DOC) in fluid communication with the exhaust system 190 (e.g.,downstream of the SCR catalyst 106 or upstream of the DPF 102) tooxidize hydrocarbons and carbon monoxide in the exhaust gas.

The sensor probe 150 may be coupled to the exhaust system 190 to detecta condition of the exhaust gas flowing through the exhaust system 190.In some implementations, the sensor probe 150 may have a portiondisposed within the exhaust system 190, such as a tip of the sensorprobe 150 may extend into a portion or the exhaust system 190. In otherimplementations, the sensor probe 150 may receive exhaust gas throughanother conduit, such as a sample pipe extending from the exhaust system190. While the sensor probe 150 is depicted as positioned downstream ofthe SCR catalyst 106, it should be understood that the sensor probe 150may be positioned at any other position of the exhaust system 190,including upstream of the DPF 102, within the DPF 102, between the DPF102 and the decomposition chamber 104, within the decomposition chamber104, between the decomposition chamber 104 and the SCR catalyst 106,within the SCR catalyst 106, or downstream of the SCR catalyst 106. Inaddition, two or more sensor probes 150 may be utilized for detecting acondition of the exhaust gas, such as two, three, four, five, or sizesensor probes 150 with each sensor probe 150 located at one of theforegoing positions of the exhaust system 190. In some implementations afirst sensor probe 150 may be upstream of the SCR catalyst 106 and asecond sensor probe 150 may be downstream of the SCR catalyst 106. Inother implementations, the first sensor probe 150 may be upstream of thedecomposition chamber 104 and the second sensor probe 150 may bedownstream of the SCR catalyst 106. In still other implementations, thefirst sensor probe 150 may be upstream of the DPF 102, and the sensorprobe 150 may be downstream of the SCR catalyst 106. Still furtherconfigurations for the sensor probes 150 may be implemented.

III. Implementations of NO_(x) Sensors

FIG. 2 depicts a block diagram of an example NH₃ oxidation catalyst 210and a NO_(x) sensor sensing material 220. The NH₃ oxidation catalyst 210may be an extruded, coated, powder or any other form of NH₃ oxidationcatalyst 210 that can be positioned before the NO_(x) sensor sensingmaterial 220. For instance, the NH₃ oxidation catalyst 210 may beinstalled before the NO_(x) sensor sensing material 220 of a NO_(x)sensor. The NH₃ oxidation catalyst 210 may be a separate catalyst thanthe DOC. That is, the NH₃ oxidation catalyst 210 may be a separatecatalyst within a housing of the NO_(x) sensor. In otherimplementations, the NH₃ oxidation catalyst 210 may be separate fromthan NO_(x) sensor or may be one part of a package with a NO_(x) sensor.In further implementations, the NH₃ oxidation catalyst 210 may comprisea layer of catalyst atop the NO_(x) sensor sensing material 220. TheNO_(x) sensor sensing material 220 may be ceramic type metal oxide, suchas yttria-stabilized zirconia (YSZ) or any other suitable NO_(x) sensorsensing material 220. The NH₃ oxidation catalyst 210 may be designed tohave high selectivity to N₂ based on the type of catalyst used, such asprecious metal or mixed oxide. For example, the NH₃ oxidation catalyst210 may be a catalyst having one or more of the following compositions:LaNiO₃, La_(0.75)Sr_(0.21)MnO₃, MeO/support Me═Co, Fe, Cr, Mn, Bi,α-Fe₂O₃, mixed oxides of V. Be, Ba, Cu, α-Fe₂O₃ Cr₂O₃, α-Fe₂O₃+ZrO₂,Co₃O₄+alumina (5-45%), thoria, ceria, zinc, and calcium oxides pelletsor extrudates, Co₃O₄+0.1-10% Li₂O pellets, grains, monoliths), Co₃O₄ orBi₂O₃ promoted by rare earth element or thorium (and may also contain atleast one of oxides of Mn, Fe, Mg, Cr or Nb), α-Fe₂O₃—MAl₂O₄—Bi₂O₃—Ce₂O₃(where M═Mg, Mn, Ca, Sr, Ba), precious metal based catalysts (e.g.,using Pt, Pd, Rh, and/or Ir) or other suitable NH₃ oxidation catalysts.In some implementations, the NH₃ oxidation catalyst 210 may be selectedbased, at least in part, on an operating temperature for the NO_(x)sensor.

As shown in FIG. 2, the NH₃ oxidation catalyst 210 selectively convertsNH₃ to N₂ while substantially permitting NO_(x) to pass through to theNO_(x) sensor sensing material 220. In some implementations, the NH₃oxidation catalyst 210 may have separate heating element for the NH₃oxidation catalyst 210 to operate at a temperature that is differentthan the temperature for the NO_(x) sensor sensing material 220. Forexample, an electric heating element or combustion heating element mayraise the temperature of the exhaust gas and/or the NH₃ oxidationcatalyst 210 to a predetermined temperature for the NH₃ oxidationcatalyst 210 to operate at to selectively convert NH₃. In otherimplementations, the operating temperature for the NH₃ oxidationcatalyst 210 may be substantially the same as that of the NO_(x) sensorsensing material 220.

FIG. 3 depicts an example block schematic configuration for a NO_(x)sensor 300. The NO_(x) sensor 300 may include a NH₃ oxidation catalyst310, a NO_(x) sensor sensing material 320, and a support component 330.The support component 330 may be any suitable component, such as asensor body, upon which the NO_(x) sensor sensing material 320 may bepositioned and used for the NO_(x) sensor 300. In some implementations,the support component 330 may be a metallic member, such as a metalplate, a metallic sensor barrel, etc. In other implementations, thesupport member 330 may be a composite material, a ceramic material, etc.The NO_(x) sensor sensing material 320 may be ceramic type metal oxide,such as yttria-stabilized zirconia (YSZ) or any other suitable NO_(x)sensing material. The NH₃ oxidation catalyst 310 may be a catalysthaving one or more of the following compositions: LaNiO₃,La_(0.75)Sr_(0.21)MnO₃, MeO/support Me═Co, Fe, Cr, Mn, Bi, α-Fe₂O₃,mixed oxides of Y, Be, Ba, Cu, α-Fe₂O₃ Cr₂O₃, α-Fe₂O₃+ZrO₂,Co₃O₄+alumina (5-15%), thoria, ceria, zinc, and calcium oxides pelletsor extrudates, Co₃O₄+0.1-10% Li₂O pellets, grains, monoliths), Co₃O₄ orBi₂O₃ promoted by rare earth element or thorium (and may also contain atleast one of oxides of Mn, Fe, Mg, Cr or Nb), α-Fe₂O₃MAl₂O₄—Bi₂O₃—Ce₂O₃(where M═Mg, Mn, Ca, Sr, Ba), precious metal based catalysts (e.g.,using Pt, Pd, Rh, and/or Ir) or other suitable NH₃ oxidation catalysts.In some implementations, the NH₃ oxidation catalyst 310 may be selectedbased, at least in part, on an operating temperature for the NO_(x)sensor 300.

In the implementation shown in FIG. 3, the NH₃ oxidation catalyst 310 ispositioned proximate (e.g., near to) the NO_(x) sensor sensing material320 such that the NH₃ oxidation catalyst 310 selectively converts NH₃ toN₂ while substantially permitting NO_(x) to pass through to the NO_(x)sensor sensing material 320. The NH₃ oxidation catalyst 310 may be aseparate catalyst than the DOC. That is, the NH₃ oxidation catalyst 310may be a separate catalyst within a housing of the NO_(x) sensor 300. Insome implementations, the NH₃ oxidation catalyst 310 may be layered atopthe NO_(x) sensor sensing material 320. For instance, the NO_(x) sensorsensing material 320 may be layered on a support component 330 of theNO_(x) sensor 300, such as a layer of YSZ within a sample chamber (e.g.,a metallic barrel) of the NO_(x) sensor 300. In some implementations,the NO_(x) sensor sensing material 320 may substantially cover an entiresurface of the support component 330 (e.g., as a layer on the interiorend of a sample chamber of a NO_(x) sensor). Suitable electrodes (e.g.,gold, platinum, palladium, etc.) for the NO_(x) sensor 300 may bepositioned relative to the NO_(x) sensor sensing material 320 (e.g.,attached, coupled, integrated into, or otherwise connected) such thatthe electrodes may detect a change in voltage across the NO_(x) sensorsensing material 320 based on the interaction of NO_(x) in an exhaustsample interacting with the NO_(x) sensor sensing material 320.

A layer of NH₃ oxidation catalyst 310 may substantially cover the NO_(x)sensor sensing material 320 such that the exhaust gas sample must passthrough the NH₃ oxidation catalyst 310 before encountering the NO_(x)sensor sensing material 320. Thus, NH₃ within the exhaust gas sample maysubstantially be oxidized by the NH₃ oxidation catalyst 310 prior toencountering the NO_(x) sensor sensing material 320. Thus, the amount ofNH₃ that may affect the detection of NO_(x) within the exhaust gassample may be substantially reduced, thereby improving the NO_(x)detection of the NO_(x) sensor 300. In some implementations, the NH₃oxidation catalyst 310 may be layered on the top and sides of a supportcomponent 330 and/or the NO_(x) sensor sensing material 320. In furtherimplementations, the NH₃ oxidation catalyst 310 may be a layer coatingthe part or the entire interior of a sample chamber of the NO_(x) sensor300 in addition to or in lieu of a layer on the NO_(x) sensor sensingmaterial 320. In some implementations, the NH₃ oxidation catalyst 310may also coat part or all of the exterior surfaces of a sample probeportion of the NO_(x) sensor 300.

In some implementations, the NH₃ oxidation catalyst 310 may be anextruded oxidation catalyst, a coating or layer of oxidation catalyst, apowdered oxidation catalyst, and/or other configuration for the NH₃oxidation catalyst 310.

FIG. 4 depicts another example block schematic configuration for aNO_(x) sensor 400 having a NH₃ oxidation catalyst 410 positionedupstream of a NO_(x) sensor sensing material 420. In the exampledepicted in FIG. 4, the NH₃ oxidation catalyst 410 is supported by thesupport component 430 of the NO_(x) sensor 400, but it should beunderstood that the NH₃ oxidation catalyst 410 described herein may beseparate from the NO_(x) sensor 400 (e.g., as a separate componentpositioned upstream in an exhaust system, as a component attached to asensor probe portion of the NO_(x) sensor 400, etc.). The supportcomponent 430 of NO_(x) sensor 400 may be any suitable component uponwhich the NO_(x) sensor sensing material 420 may be positioned and usedfor the NO_(x) sensor 400. In some implementations the support component430 may be a metallic member, such as a metal plate, a metallic sensorbarrel, etc. In other implementations, the support member 430 may be acomposite material, a ceramic material, etc. The NO_(x) sensor sensingmaterial 420 may be ceramic type metal oxide, such as yttria-stabilizedzirconia (YSZ) or any other suitable NO_(x) sensing material. The NH₃oxidation catalyst 410 may be a catalyst having one or more of thefollowing compositions: LaNiO₃, La_(0.75)Sr_(0.21)MnO₃, MeO/supportMe═Co, Fe, Cr, Mn, Bi, α-Fe₂O₃, mixed oxides of Y, Be, Ba, Cu, α-Fe₂O₃Cr₂O₃, α-Fe₂O₃ Cr₂O₃, αFe₂O₃+ZrO₂, Co₃O₄+alumina (5-15%), thoria, ceria,zinc, and calcium oxides pellets or extrudates, Co₃O₄+0.1-10% Li₂Opellets, grains, monoliths), Co₃O₄ or Bi₂O₃ promoted by rare earthelement or thorium (and may also contain at least one of oxides of Mn,Fe, Mg, Cr or Nb), α-Fe₂O₃—MAl₂O₄—Bi₂O₃—Ce₂O₃ (where M═Mg, Mn, Ca, Sr,Ba), precious metal based catalysts (e.g., using Pt, Pd, Rh, and/or Ir)or other suitable NH₃ oxidation catalysts. In some implementations, theNH₃ oxidation catalyst 410 may be selected based, at least in part, onan operating temperature for the NO_(x) sensor 400.

In the implementation shown in FIG. 4, the NH₃ oxidation catalyst 410 ispositioned upstream of the NO_(x) sensor sensing material 420 such thatthe NH₃ oxidation catalyst 410 selectively converts NH₃ to N₂ whilesubstantially permitting NO_(x) to pass through to the NO_(x) sensorsensing material 420. In some implementations, the NH₃ oxidationcatalyst 410 may be coated on a support structure, such as a filter orsubstrate body or a portion of the support component 430, upstream ofthe NO_(x) sensor sensing material 420. The NH₃ oxidation catalyst 410may be a separate catalyst than the DOC. That is, the NH₃ oxidationcatalyst 410 may be a separate catalyst within a housing of the NO_(x)sensor 400. For instance, the NO_(x) sensor sensing material 420 may belayered on a portion of the support component 430 of the NO_(x) sensor400, such as a layer of YSZ, within a sample chamber (e.g., a metallicbarrel) of the NO_(x) sensor 400. In some implementations, the NO_(x)sensor sensing material 420 may substantially cover an entire surface ofthe support component 430 (e.g., as a layer on the interior end of asample chamber of a NO_(x) sensor). Suitable electrodes (e.g., gold,platinum, palladium, etc.) for the NO_(x) sensor 400 may be positionedrelative to the NO_(x) sensor sensing material 420 (e.g., attached,coupled, integrated into, or otherwise connected) such that theelectrodes may detect a change in voltage across the NO_(x) sensorsensing material 420 based on the interaction of NO_(x) in an exhaustsample interacting with the NO_(x) sensor sensing material 420.

In some implementations, the NH₃ oxidation catalyst 410 may be appliedto a portion of the support component 430 or a separate componentupstream of the layer of NO_(x) sensor sensing material 420. Forexample, the NH₃ oxidation catalyst 410 may be an extrudedfilter/substrate or coated filter/substrate that may be positionedupstream of the NO_(x) sensor sensing material 420. In someimplementations, the NH₃ oxidation catalyst 410 may be affixed to thesupport component 430 of the NO_(x) sensor 400. Thus, the NH₃ oxidationcatalyst 410 may be spaced apart from the NO_(x) sensor sensing material420 of the NO_(x) sensor 400. In some implementations, a heating elementmay be provided to heat the NH₃ oxidation catalyst 410 and/or theexhaust gas sample encountering the NH₃ oxidation catalyst 410 such thatthe NH₃ oxidation catalyst 410 and/or the exhaust gas sample operates ata temperature that is different than the temperature for the NO_(x)sensor sensing material 420. For example, an electric heating element orcombustion heating element may raise the temperature of the exhaust gassample and/or the NH₃ oxidation catalyst 410 to a predeterminedtemperature for the NH₃ oxidation catalyst 410 to operate at toselectively convert NH₃. In an implementation, a portion of a samplechamber housing the NH₃ oxidation catalyst 410 may be insulated relativeto a portion of the sample chamber housing the NO_(x) sensor sensingmaterial 420. Thus, the portion of the sample chamber housing the NH₃oxidation catalyst 410 may be heated (e.g., via resistive/electricalheating and/or combustion heating) for the NH₃ oxidation catalyst 410 tooperate at a first temperature while the insulation insulates theportion of the sample chamber housing the NO_(x) sensor sensing material420 to operate at a second temperature different from the firsttemperature.

In some other implementations, the NH₃ oxidation catalyst 410 may be apowdered NH₃ oxidation catalyst 410 that may be filled into a samplechamber of the NO_(x) sensor 400 with a membrane to contain the NH₃oxidation catalyst 410 within the sample chamber while permitting theexhaust gas sample containing NH₃ and/or NO_(x) to pass through to theNO_(x) sensor sensing material 420.

In any of the foregoing describe implementations and/or combinationsthereof, the NH₃ oxidation catalyst 410 may also coat part or the entireinterior of a sample chamber of the NO_(x) sensor 400. In any of theforegoing describe implementations and/or combinations thereof, the NH₃oxidation catalyst 410 may also coat part or all of the exteriorsurfaces of a sample probe portion of the NO_(x) sensor 400.

FIG. 5 is a block diagram of an example NH₃ oxidation catalyst 510 and aNO_(x) sensor sensing material 520 for yet another NO_(x) sensor 500.The NH₃ oxidation catalyst 510 may be an extruded, coated, powder or anyother form of NH₃, oxidation catalyst 510 that can be positioned beforethe NO_(x) sensor sensing material 520. For instance, the NH₃ oxidationcatalyst 510 may be installed before the NO_(x) sensor sensing material520 of a NO_(x) sensor. In other implementations, the NH₃ oxidationcatalyst 510 may be separate from than NO_(x) sensor 500 or may be onepart of a package with a NO_(x) sensor 500. In further implementations,the NH₃ oxidation catalyst 510 may comprise a layer of catalyst atop theNO_(x) sensor sensing material 520. The NO_(x) sensor sensing material520 may be ceramic type metal oxide, such as yttria-stabilized zirconia(YSZ) or any other suitable NO_(x) sensing material. The NH₃ oxidationcatalyst 510 may be designed to have high selectivity to N₂ based on thetype of catalyst used, such as precious metal or mixed oxide. Forexample, the NH₃ oxidation catalyst 510 may be a catalyst having one ormore of the following compositions: LaNiO₃, La_(0.75)Sr_(0.21)MnO₃,MeO/support Me═Co, Fe, Cr, Mn, Bi, α-Fe₂O₃, mixed oxides of Y, Be, Ba,Cu, α-Fe₂O₃ Cr₂O₃, α-Fe₂O₃+ZrO₂, Co₃O₄+alumina (5-15%), thoria, coria,zinc, and calcium oxides pellets or extrudates, Co₃O₄+0.1-10% Li₂Opellets, grains, monoliths), Co₃O₄ or Bi₂O₃ promoted by rare earthelement or thorium (and may also contain at least one of oxides of Mn,Fe, Mg, Cr or Nb), α-Fe₂O₃—MAl₂O₄—Bi₂O₃—Ce₂O₃ (where M═Mg, Mn, Ca, Sr,Ba), precious metal based catalysts (e.g., using Pt, Pd, Rh, and/or H)or other suitable NH₃ oxidation catalysts. In some implementations, theNH₃ oxidation catalyst 510 may be selected based, at least in part, onan operating temperature for the NO_(x) sensor 500.

As shown in FIG. 5, the NH₃ oxidation catalyst 510 selectively convertsNH₃ to N₂ while substantially permitting NO_(x) to pass through to theNO_(x) sensor sensing material 520. The NH₃ oxidation catalyst 510 maybe a separate catalyst than the DOC. That is, the NH₃ oxidation catalyst510 may be a separate catalyst within a housing of the NO_(x) sensor500. In some implementations, the NH₃ oxidation catalyst 510 may havefirst heating and/or cooling element 512 for the NH₃ oxidation catalyst510 to operate at a first temperature that is different than a secondtemperature for the NO_(x) sensor sensing material 520. For example, anelectric heating and/or cooling element or combustion heating and/orcooling element 512 may raise or lower the temperature of the exhaustgas and/or the NH₃ oxidation catalyst 510 to a predetermined firsttemperature for the NH₃ oxidation catalyst 510 to operate at toselectively convert NH₃.

In some implementations, the NO_(x) sensor sensing material 520 may havesecond heating and/or cooling element 522 for the NO_(x) sensor sensingmaterial 520 to operate at a second temperature that is different thanthe first temperature for the NH₃ oxidation catalyst 510. For example,an electric heating and/or cooling element or combustion heating and/orcooling element 522 may raise the temperature of the exhaust gas and/orthe NO_(x) sensor sensing material 520 to a predetermined secondtemperature for the NO_(x) sensor sensing material 520 to operate at toselectively convert NO_(x). In other implementations, the firsttemperature for the NH₃ oxidation catalyst 510 may be substantially thesame as the second temperature for the NO_(x) sensor sensing material520.

Any of the foregoing NO_(x) sensors 300, 400, 500 may be coupled to aportion of an exhaust system, such as exhaust system 190 of FIG. 1, suchthat the NO_(x) content within the exhaust gas may be sampled andmeasured, such as upstream of the DPF 102, within the DPF 102, betweenthe DPF 102 and the decomposition chamber 104, within the decompositionchamber 104, between the decomposition chamber 104 and the SCR catalyst106, within the SCR catalyst 106, downstream of the SCR catalyst 106, orany other portion of the exhaust system 190. In some implementations,several NO_(x) sensors 300, 400, 500 may be used at any combination ofthe foregoing portions of the exhaust system 190.

The term “controller” encompasses all kinds of apparatus, devices, andmachines for processing data, including by way of example a programmableprocessor, a computer, a system on a chip, or multiple ones, a portionof a programmed processor, or combinations of the foregoing. Theapparatus can include special purpose logic circuitry, e.g., an FPGA oran ASIC. The apparatus can also include, in addition to hardware, codethat creates an execution environment for the computer program inquestion, e.g., code that constitutes processor firmware, a protocolstack, a database management system, an operating system, across-platform runtime environment, a virtual machine, or a combinationof one or more of them. The apparatus and execution environment canrealize various different computing model infrastructures, such asdistributed computing and grid computing infrastructures.

A computer program (also known as a program, script, or code) can bewritten in any form of programming language, including compiled orinterpreted languages, declarative or procedural languages, and it canbe deployed in any form, including as a standalone program or as amodule, component, subroutine, object, or other unit suitable for use ina computing environment. A computer program may, but need not,correspond to a file in a file system. A program can be stored in aportion of a file that holds other programs or data (e.g., one or morescripts stored in a markup language document), in a single filededicated to the program in question, or in multiple coordinated files(e.g., files that store one or more modules, sub programs, or portionsof code).

While this specification contains many specific implementation details,these should not be construed as limitations on the scope of what may beclaimed, but rather as descriptions of features specific to particularimplementations. Certain features described in this specification in thecontext of separate implementations can also be implemented incombination in a single implementation. Conversely, various featuresdescribed in the context of a single implementation can also beimplemented in multiple implementations separately or in any suitablesubcombination. Moreover, although features may be described above asacting in certain combinations and even initially claimed as such, oneor more features from a claimed combination can in some cases be excisedfrom the combination, and the claimed combination may be directed to asubcombination or variation of a subcombination.

As utilized herein, the term “substantially” and any similar terms areintended to have a broad meaning in harmony with the common and acceptedusage by those of ordinary skill in the art to which the subject matterof this disclosure pertains. It should be understood by those of skillin the art who review this disclosure that these terms are intended toallow a description of certain features described and claimed withoutrestricting the scope of these features to the precise numerical rangesprovided unless otherwise noted. Accordingly, these terms should beinterpreted as indicating that insubstantial or inconsequentialmodifications or alterations of the subject matter described and claimedare considered to be within the scope of the invention as recited in theappended claims. Additionally, it is noted that limitations in theclaims should not be interpreted as constituting “means plus function”limitations under the United States patent laws in the event that theterm “means” is not used therein.

The terms “coupled,” “connected,” and the like as used herein mean thejoining of two components directly or indirectly to one another. Suchjoining may be stationary (e.g., permanent) or moveable (e.g., removableor releasable). Such joining may be achieved with the two components orthe two components and any additional intermediate components beingintegrally formed as a single unitary body with one another or with thetwo components or the two components and any additional intermediatecomponents being attached to one another.

The terms “fluidly coupled,” “in fluid communication,” and the like asused herein mean the two components or objects have a pathway formedbetween the two components or objects in which a fluid, such as water,air, gaseous reductant, gaseous ammonia, etc., may flow, either with orwithout intervening components or objects. Examples of fluid couplingsor configurations for enabling fluid communication may include piping,channels, or any other suitable components for enabling the flow of afluid from one component or object to another.

It is important to note that the construction and arrangement of thesystem shown in the various exemplary implementations is illustrativeonly and not restrictive in character. All changes and modificationsthat come within the spirit and/or scope of the describedimplementations are desired to be protected. It should be understoodthat some features may not be necessary and implementations lacking thevarious features may be contemplated as within the scope of theapplication, the scope being defined by the claims that follow. Inreading the claims, it is intended that when words such as “a,” “an,”“at least one,” or “at least one portion” are used there is no intentionto limit the claim to only one item unless specifically stated to thecontrary in the claim. When the language “at least a portion” and/or “aportion” is used the item can include a portion and/or the entire itemunless specifically stated to the contrary.

What is claimed is:
 1. A NOx sensor comprising: a NOx sensing material;an NH3 oxidation catalyst coupled to the NOx sensing material andlocated upstream of the NOx sensing material; and a temperature controlelement operatively coupled to the NH3 oxidation catalyst and configuredto heat or cool the NH3 oxidation catalyst so as to control an operatingtemperature of the NH3 oxidation catalyst.
 2. The NOx sensor of claim 1,wherein the temperature control element is configured to cause the NH3oxidation catalyst to operate at a first temperature that is differentfrom a second temperature of the NOx sensing material.
 3. The NOx sensorof claim 1, wherein the temperature control element is configured tocause the NH3 oxidation catalyst to operate at a first temperature thatis the same as a second temperature of the NOx sensing material.
 4. TheNOx sensor of claim 1, wherein: the temperature control element is afirst temperature control element, and the NOx sensor further comprisesa second temperature control element operatively coupled to the NOxsensing material and configured to heat or cool the NOx sensing materialso as to control an operating temperature of the NOx sensing material.5. The NOx sensor of claim 1, wherein the NH3 oxidation catalystcomprises an extruded catalyst.
 6. The NOx sensor of claim 1, whereinthe NH3 oxidation catalyst comprises a coated substrate.